Slip and lock system dome construction system

ABSTRACT

A method of constructing a dome structure using prefabricated insulated panels with a unique edge and a slip and lock feature, which allows assembly without a skeleton rib or infrastructure; or an elaborate framework of internal scaffolding; or the need of rings; or the need for screws, bolts, clamps and glue. The sealed structure will present a seamless exterior dome wall where the panels are completely integrated, sealed, and locked with each other and the flooring to form a monolithic structure or a circular wall as desired. The exterior of the dome structure is quickly ready for insulation and a finish of concrete, stucco, synthetic stucco, or other exterior materials such as fiberglass panels.

FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT

[0001] Not Applicable

BACKGROUND OF INVENTION

[0002] This invention is designed to construct a permanent dome like structure using prefabricated panels connected to each other and to a permanent load bearing flooring with simple locks. Some current dome construction patents using panels are designed to be to be assembled with bolts, clamps, or fasteners such as U.S. Pat. No. 6,276,095 Tripsianes dated Aug. 21, 2001 and U.S. Pat. No. 4,720,947 Yacabonic dated Jan. 26, 1988. Another method requires multiple panels to be attached to a supporting ring as claimed in U.S. Pat. No. 4,805,371 DeJong et. al, dated Feb. 21, 1989 and U.S. Pat. No. 4,798,032 Rose Jr dated Jan. 17, 1989 requires panels of polystyrene to be stacked and glued together. All methods are labor intensive, require some degree of skilled labor, and demand a great deal of on site assembly time.

SUMMARY OF THE INVENTION

[0003] The easy slip and lock design of the invention allows very quick assembly of a durable and permanent or semi-permanent dwelling. The system eliminates the need for elaborate ring bracing, scaffolding, nuts, bolts or fasteners assembly, glued stacked panels or expert craftsman. As few as three workmen and a small crane can assemble the structure in hours and lock into place by the end of day. Once the last panel is slipped into place, the structure will stand without additional construction reinforcement. The dome assumes the complete characteristics of a monolithic dome structure when the locking keyholes, sleeves, and seams are sealed with the appropriate construction material. The objective of my slip and lock system invention is to provide affordable housing which is fire-resistant, insulated, insect proof, energy efficient, maintenance free, and almost windproof through a unique system that reduces labor cost, material cost, and time of construction.

BRIEF DESCRIPTION OF DRAWINGS

[0004]FIG. 1

[0005] This drawing highlights the 45-degree edge angle of the panels and the sealant grove created when the panels are joined. The 45-degree angle allows the panels to be placed without the aid of interior scaffolding, bracing, or skeleton infrastructure. Except for the first and last panel, the panels will be slipped into position in succession whereby the exterior edge of the succeeding panel will over lap the interior ledge of the panel already in place. The first panel will have interior edges, and in order to facilitate placement, the last panel will have exterior edges.

[0006]FIG. 2

[0007] This drawing highlights the keyholes and the keys, which will lock down the panel to the flooring after the sleeves are filled with concrete. The top half of the stabilizing rebar key will be inserted straight into matching horizontal sleeves in the interior wall at base of the panel. To accomplish this insert, the keys are actually inserted into the horizontal sleeves located at the interior base of the panel first and the lower half of the key is dropped into the flooring sleeve as the panel is lowered into place. A rebar key is placed in the counter balance sleeve at the vertical flooring edge and in a matching sleeve in the exterior of the panel near the base.

[0008]FIG. 3

[0009] This drawing highlights the vertical stabilization keyhole created when two panels are placed side by side. Each panel contributes one-half of the keyhole that is molded in the exterior edge of the 45 degree angle. Each panel edge also contributes half of the sealant groove. The drawing shows embedded rebar as the connecting link and rebar bent in the shape of a hook and tail as the key. After the key is tapped into place, the entire keyhole and groove will be sealed with concrete or like material

[0010]FIG. 4

[0011] This drawing highlights an overall picture of how each panel is interlocked together and to the flooring until the structure is completed. Note the Exterior Edge of Panel B over laps the Interior Edge of Panel A. Panel B shows the flooring locks and the counter-balance key lock common to all panels.

DESCRIPTION

[0012] 1. The description will utilize prefabricated concrete and rebar as the material for the dome panels, which will be erected on concrete slab flooring. Each panel will be triangular in shape with a slightly convex curved base sufficient to form the circumference of a dome when all panels are in place. The base will have a thickness, or footprint, approximately four times the thickness of the top of the panel and reach in an arch from the flooring to the top of the dome structure. Note invention could also be used to construct an open top dome or a circular wall. Each panel will have 45-degree slant vertical edges with the outer edge cupped to create a one-half inch deep channel when two panels are slipped together The edges of each panel will also have 3-6 keyholes, depending on panel size and thickness, of exposed rebar or eyebolts, approximately 2.5 inches deep and 6 inches wide, which will be created when two panels are slipped into place side by side. The exposed rebar or eye bolts in the keyholes will be connected with rebar keys (hooks) to form a double lock, along with the 45 degree overlapping edge, to secure each panel in place with the neighboring panel. These keyhole connections will provide horizontal stability during construction and strength to the completed structure. Panels must be slipped in place in secession. To assemble counter-clockwise, the panels will be slipped into position in succession whereby the exterior edge of the succeeding panel will over lap the interior ledge of the panel already in place. To facilitate the placement of the last panel, the first panel will have two interior edges and the last panel will have two exterior edges. The 45-degree edge angle allows the succeeding panel to be held in place by all of the panels already locked in place. To lock the panels to the flooring, the panels have horizontal keyhole sleeves in the interior side of the panel base, approx. 8-14 inches apart and four to eight inches deep (depending on size of the panel), that will receive the top half of a 90-degree angle rebar key. The flooring will have a matching strategically imbedded sleeve near the rim of the concrete floor slab to receive the bottom half of the 90-degree rebar key. To accomplish this insert, the keys are actually inserted into the horizontal sleeves located at the interior base of the panel first and the lower half of the key is dropped into the flooring sleeve as the panel is lowered into place. This technique allows the keys to move sideways or up and down which allows the base of the panel to be slipped onto the concrete flooring with ease. The flooring locking keys are now in place and ready for concrete sealing.

[0013] 2. The exterior of the panel base will have a counter balance sleeve keyhole, approximately at the apex of the arc and about 3 inches from the bottom of the panel base, which will match a similar keyhole sleeve approximately 3 inches from the flooring surface in the vertical flooring edge. A rebar key in the shape of a square staple will be slipped into place to stabilize the panel until the succeeding or last panel is locked in placed.

[0014] 3. The structure is now a freestanding semi-permanent structure, which may be dismantled by removing the panels in reverse order.

[0015] 4. The panels flooring seams, sleeves, keyholes, and rebar keys are sealed with concrete to solidify the structure as a permeant shelter. The panels are now securely locked together and to the slab flooring with rebar and cement to form a monolithic structure. Except for window, door, and vent openings molded into the panels, the exterior of the structure is ready for insulation and a finish of concrete, stucco, or other exterior material such as fiberglass panels. 

1. I hereby claim priority as to date of filing in accordance with Utility Provisional Patent application No. 60/367,150 dated Mar. 25,
 2002. 2. I claim a method of building a dome structure starting from a prepared flooring utilizing a plurality of prefabricated panels that are triangular in shape with a slightly convex curved base sufficient to form the circumference of a dome when all panels are in place. The panels may be made of lightweight concrete and rebar or other materials such as fiberglass, vinyl, hardened structural foam or wood.
 3. A method of building a dome structure with an open or closed top.
 4. A method of building a circular wall.
 5. The edges of each panel will have an approximate 45-degree angle slant, which will allow each panel edge to over lap the edge of the preceding panel by approximately 50% of the thickness of the panel regardless of the curvature of the panel. One 45-degree edge of the panel will be external and the other internal: The panels will be slipped into position in succession whereby the exterior edge of the succeeding panel will over lap the interior ledge of the adjacent panel that is already locked in place. The first and last panel will be an exception to the edge lap over sequence of interior and exterior edges. The first panel will have two interior edges and the last panel will have two exterior edges to facilitate placement of the last panel.
 6. Panels may form a dome with the panels meeting at the top or have an opening at the top of a dome or form a circular wall.
 7. Each new panel is held in place, by the panels already in place, without the aid of scaffolding or skeletal framework.
 8. The 45-degree panel angles fit together to transfer weight and external forces in the same manner as a monolithic structure.
 9. Panels will be locked together by one or more keyholes molded into the 45-degree panel edge. Keyholes will be matched to a keyhole in the slant edge of the adjacent panel. Rebar keys will be inserted into the keyholes to lock each panel to neighboring panel.
 10. Panels will be locked to the flooring by rebar keys and concrete. Sleeves imbedded horizontally in the interior base of the panel will receive a rebar key to lock the panel to a matching sleeve imbedded vertically in the concrete flooring. Sleeves imbedded horizontally in the exterior base of each panel will be matched to a horizontal sleeve in the vertical edge of the floor.
 11. Prior to sealing the keyholes, seams, etc with concrete, the structure may be dismantled by removing the panels in reverse order.
 12. Sealing all sleeves, keyholes, keys, and flooring edges with concrete solidifies the panels into a permanent monolithic structure. 